Synthetic fuel production method

ABSTRACT

A method of producing a synthetic fuel by treating bituminous coal fines with a tall-oil mix that may include enhancer additives that either increase the chemical change capability of the tall-oil mix or reduce the cost of the tall-oil mix while maintaining the chemical change rate, and/or an additive of tar decanter sludge and light cycle oil. Enhancers include poly vinyl acetate (PVA) and/or ethyl vinyl acetate (EVA), glycol, lignosulfonate, beet sugar bottoms, corn bottoms, brewery bottoms, vegetable tall oil, vegetable oil, and/or spent frying oil. The tall-oil mix is reacted with the coal, resulting in a cost effective and industry-usable source of synthetic fuel. When the enhanced tall-oil mix is reacted with bituminous metallurgical coal, the product is a synthetic fuel.

[0001] This application is a continuation-in-part of currently pendingpatent application Ser. No. 10/429,343, filed on May 5, 2003, which wasa continuation-in-part of Ser. No. 09/939,229, filed on Aug. 24, 2001,and issued as U.S. Pat. No. 6,558,442 on May 6, 2003, and claimspriority under 35 U.S.C. 120 therefrom and also claims priority under 35U.S.C. 119 from provisional application No. 60/228,976, filed Aug. 30,2000.

BACKGROUND INFORMATION

[0002] 1. Field of the Invention

[0003] This invention relates generally to the production ofnon-traditional fuels, often referred to as synthetic fuels. Moreparticularly, this invention relates to the creation of such fuels usingexisting stockpiles of coal fines, coal dust, and other similar smallparticles of virgin coal. More particularly yet, this invention relatesto using emulsions of tall oil and tall oil pitch, a by-product of thepaper industry, in the creation of such fuels.

[0004] 2. Description of the Prior Art

[0005] For centuries coal has been mined as a source of fuel. Duringthese years, numerous improvements have been made to increase miningefficiency and safety, and to improve the overall quality and purity ofthe end product. However, one drawback of coal mining is the by-productof coal fines that frequently end up abandoned into waste pits scatteredthroughout the countryside. These coal fines constitute up to 20% of thecoal being mined, and are found in the waste stream generated by theinitial washing and filtering of the coal from the mine. Although coalfines include particles as small as dust motes, the term can alsoinclude pieces of coal up to about one-half inch in diameter. Thismaterial has traditionally been abandoned to waste, deposited in theform of “coal tips,” because it has been economically inefficient tohandle such sizes as they are brought to the point of being burned fortheir energy content. As a result, literally millions of tons of suchmaterial has been produced over the years, and currently lays dormant ator near mining sites. Not only does this non-use pose a great waste ofvaluable natural fuel resources, but it also poses a threat to thesurrounding environment. In addition to respiratory hazards presented bythe dust-sized particles, the large surface area associated withstockpiles of such particles poses a high risk for spontaneouscombustion such as the type known as a dust explosion.

[0006] These environmental issues, together with the growing concern ofthe limited existing amount of natural fuel resources, has led to anincreased interest in utilizing these dormant coal fines, as well asdeveloping an alternative use of virgin coal.

[0007] Attempts to utilize coals fines as fuel include the methoddisclosed in White (U.S. Pat. No. 5,916,826; issued 1999), which teachesa method of pelletizing and briquetting coal fines using bio-bindersproduced by liquefaction of biomass. Unfortunately, this process isextremely costly, primarily because of the required liquefactionprocess, which is carried out in an oxygen-free environment at elevatedtemperatures, e.g. between 450 degrees and 700 degrees F., and elevatedpressures, typically between 200 psi and 3,000 psi. The resulting liquidis then sprayed on coal fines that have themselves been heated to atleast 250 degrees F., after which the coal and the liquid are allowed toreact at about 300-400 degrees F. Although this method serves toalleviate certain environmental concerns, the high costs of reclaimingcoal using this process undercuts the basic usefulness of the inventionitself.

[0008] Another recent example of the attempt to use coal fines as fuel,Ford (U.S. Pat. No. 5,453,103; issued 1995), discloses a method offorming solid fuel pieces from coal fines by combining and mixing water,hydrochloric acid, a conditioner, and a polyvinyl acetate (PVA) emulsionand then compressing the resulting slurry into solid fuel pieces.Although this process is effective, its requirement of PVA, which mustbe separately created for this particular use, makes the F rd processeconomically and environmentally inefficient in comparison with aprocess founded entirely on the use of constituents that are alreadypresent, and which some of the constituents are not being devoted to anyeconomical purpose. In other words, a process that consumed both coalfine waste and another hitherto waste element would be more desirablethan the Ford process.

[0009] A process that does use as input primarily waste products fromother industrial operations is revealed by Major (U.S. Pat. No.6,013,116; issued 2000), which teaches a composition for binding coalfines into larger pieces, typically called briquets. The briquet-bindercomposition of Major can be produced using an asphalt base, sodiumcarbonate pulping liquor, and a surfactant. However, for optimal bindingresults, strength-increasing additives such as latex, vinyl derivatives,cellulose, cellulose derivatives, peat moss, starch, starch derivatives,and various' pulps need to be added to the binder composition. (Theaddition of lignosulfate, cement, rubber, and plastics is also taught byMajor.) Although this process does use various waste products of otherindustries in transforming coal fines into a more usable fuel source,the complexity of the binding material makes the process quite complex,thereby reducing the economic viability of the overall method.

[0010] An older process of reclaiming coal fines is disclosed inDondelewski (U.S. Pat. No. 4,357,145; issued 1982). In Dondelewski, coalfines are combined with a liquid by-product of the pulp and paperindustry, namely a liquid containing tall oil, tall oil pitch, ormixtures thereof (“tall oil mix”). Tall oil and tall oil pitch areby-products from the digestion of wood by the Kraft (sulfate) papermanufacturing process. In the Dondelewski method, the coal fines arefirst put into the form of a slurry by mixing them with water. After theslurry has been formed, it is fed to a conditioning tank where it ismixed with tall oil mix. In the conditioning tank, the tall oil mixadheres to and thus coats the surfaces of the individual coal particles,after which the slurry of now-coated coal particles and excess tall oilmix is introduced into a flotation cell, where the coated coal particlesare separated from the excess tall oil mix and most of the water. Vacuumfilters, vibratory screens and centrifuges may be used to remove excessliquid, a necessary step since most coal-consuming furnaces cannottolerate a high moisture content. Again, the process of Dondelewski hasas its feed stock predominantly industrial by-products, it is veryprocess intensive, first requiring large vats to mix the coal slurry andtall oil mix, then further processing to remove excess water and talloil mix followed by drying the end product. Thus, the method ofDondelewski does not satisfy the condition of using industrialby-products to produce a synthetic fuel that is economically competitivewith the fuels that the synthetic fuel is intended to supplant, or whichin general is in competition with it as a fuel source.

[0011] Therefore, what is needed is an economical and environmentallyfriendly method of using industrial by-products traditionally discardedas waste as the feed stock for a new fuel. What is more specificallyneeded, in view of the millions of tons of coal fines depositedthroughout the landscape, is such a method that uses coals fines as allor part of the feed stock. Finally, what is needed is such a processthat by whatever means results in a fuel that is economically viable inthe marketplace, so that industries now holding hegemony over thereferenced industrial by-products, and in particular the coal fines,will be induced to use up those by-products, removing them from thecategory of stored and hazardous waste.

BRIEF SUMMARY OF THE INVENTION

[0012] It is an object of the present invention to use fines ofbituminous coal and other industrial by-products in the creation of acommercially viable fuel. Another object of the present invention is touse such hitherto waste products in a process that is environmentallyfriendly. A further object of the invention is to provide such a processthat will reduce the overall cost of production, so as to provideindustry the economic incentives to make use of the coal fines.

[0013] The term “tall oil mix” as used hereinafter shall refer to talloil, tall oil pitch, or any combination thereof. This tall oil mix maybe modified to the extent that fatty acids, rosin acids, sterols andother constituents may be added or subtracted. The term “coal fines” asused hereinafter is a collective designation for coal particles ofbituminous coal, including steam or metallurgical coal fines, coal dust,and all other coal particles that can be used as feedstock foralternative fuels, as well as for bituminous steam or metallurgical coalfines, coal dust, and all other coal particles that could be useddirectly as a traditional fuel source, but for the fact that they aretoo small to be able to reach their full economic potential given thepresent technology. The term “tall oil emulsion” shall refer to anytall-oil-mix, suspension or solution, in water, with or withoutenhancers.

[0014] The method of the present invention meets the invention'sobjectives by combining the solids of tall oil mix with coal fines, andmore particularly with all or essentially all of the individualparticles constituting the coal fines being processed. Moreparticularly, the method of the present invention involves spraying talloil emulsion into a stream of coal fines, typically an air stream ofcoal fines formed by letting the coal fines fall under gravity past aspray of tall oil emulsion directed substantially at right angles to thestream.

[0015] As mentioned earlier, tall oil and tall oil pitch are by-productsof the digestion of wood by the Kraft (sulfate) paper manufacturingprocess. Tall oil is 100% organic, non-toxic and non-hazardous tohandle. Based on tests carried out on behalf of the inventor, it appearsthat tall oil reacts chemically with the coal fines after the twocomponents have been brought together according to the method of thepresent invention. The fuel produced by the present invention is asynthetic fuel in the sense of a synthetic fuel being a fuel “which doesnot exist in nature . . . [but rather] is synthesized or manufacturedfrom varieties of fossil fuels which cannot be used conveniently intheir original form.” [McGraw-Hill Encyclopedia of Science andTechnology, McGraw-Hill, Inc., 1982.] Moreover, it is a synthetic fuelproduced by a method resulting in a significant chemical change, basedupon the infra-red absorption spectra of the fuel in comparison with theinfra-red absorption spectra of the fuel's constituents prior toprocessing.

[0016] Additionally, when tall oil is combined with coal fines it willcontribute in excess of 50,000 Btu's per gallon applied, based upon a40% solids content tall oil emulsion. It is to be emphasized here thatunlike prior-art uses of tall oil, the present method is not aimed atsimply producing agglomerations of the basic coal particles. Rather, itis used to produce fuel that continues to exist in small particulateform, but with the tall-oil-mix solids combined with the particulate. Incarrying out this method, tall oil emulsion has numerous processadvantages over the prior art methods. It can be directly sprayed intopassing or free falling coal fines, therefore eliminating the necessityof having large mixing vats to coat the coal fines. Additionally,directly applying tall oil emulsion into the coal fines eliminates theneed to separate the coal fines from the tall oil mixing slurry, astaught in the prior art. Elimination of these cost intensive processsteps makes the processing of coal fines into a usable fuel a moreeconomical option, and therefore provides an incentive to industry touse this fuel source. A further benefit of using tall oil emulsion isthat, in contrast with the relevant prior art described above, it may beapplied to the coal fines at a specific rate and specific concentration,without requiring removal of excess material with centrifuges and/ordryers. For example, the tall oil emulsion may be adjusted to containthe desired amount of tall oil to be applied to the coal fines, thuseliminating waste of valuable tall oil resources. The emulsion may besimply sprayed through various nozzles into the coal fines, either infree fall or on conveyor belts. Once sprayed, the treated coal finesneed no or little drying, as the water from the emulsion evaporates aspart of the process. The treated coal fines may then be sent to anagitator to further facilitate even distribution of the emulsionthroughout the coal fines, and/or continue on to be agglomerated bybriquetting or pelletizing apparatus. Nevertheless, it is the process ofcombining the coal fines with the tall-oil solids that constitutes theheart of the present invention.

[0017] Tall oil emulsions may be prepared in a variety of methods thatare well known in the art. Applicants of the present invention havediscovered that certain additives or “enhancers” to the tall-oil mixincrease the chemical change or reduce the cost while maintainingchemical change that takes place in the coal and enhance the fuel valueof the synthetic fuel according to the present invention. Depending uponthe specific enhancer, the enhancer is added to the tall oil pitchbefore emulsification or added to the tall-oil mix after emulsification.For example, in an “enhanced tall-oil mix,” poly vinyl acetate (PVA)and/or ethyl vinyl acetate (EVA) is added in an aqueous form with asolids content of between 40 and 55 percent as an enhancer to a tall-oilmix. Depending upon the specific enhancer, the amount of the enhancerthat may be added to the enhanced-tall-oil mix ranges from 1 to 50percent. The use of PVA and/or EVA enhancer reduces by approximately 30%the application rate of the tall-oil mix to the coal fines over that ofan unenhanced tall-oil mix. Other suitable materials that serve asenhancers include urea, glycol, lignosulfonate, vegetable materials,such as beet sugar bottoms, molasses, corn bottoms, brewery bottoms,vegetable tall oil, vegetable oil, vegetable pitch, and/or spent fryingoil. Again, one or more of these materials is added to the tall-oil mixto create an enhanced tall-oil mix that reduces the cost of producingthe synthetic fuel, either by allowing the use of less expensivematerials while maintaining chemical change properties, or increasingthe chemical change that takes place in the coal, thereby reducing therate of application and, thus, reducing overall costs. The term“enhanced tall-oil mix” as used hereinafter, includes a tall-oil mix towhich at least one of the above-mentioned enhancers has been added.

[0018] A further development of the method of the present inventionincludes combining a waste material called tar decanter sludge (TDS), aby-product of the steel industry, with the enhanced tall-oil mix, acaustic solution, and water to produce an enhanced-TDS-tall-oil mix thatis then applied as the chemical change agent to bituminous coal fines,to produce a synthetic fuel. Although not necessary to obtain thedesired chemical change, light cycle oil (LCO) is preferably also addedto the TDS as a thinner, because it improves the mixing process. Beforethe enhanced-TDS-tall-oil mix is applied to the bituminous coal fines,in facilities where mechanical mixing devices are not available, thecomponents are mixed in batches and combined with one another via pipesystems in a dynamic manner and a homogeneous mix is accomplished viarecirculation and a grinding pump. A particularly useful application ofthis method is to apply the enhanced-TDS-tall-oil mix to bituminousmetallurgical coal fines to produce a synthetic fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention is described with reference to theaccompanying drawings. In the drawings, like reference numbers indicateidentical or functionally similar elements. Additionally, the left-mostdigit(s) of a reference number identifies the drawing in which thereference number first appears.

[0020]FIG. 1 is diagrammatic view of the application process in whichemulsified tall oil is joined with coal fines.

[0021]FIG. 2 is a graphical Fourier Transform Infrared (FTIR) analysis,comparing a solid synthetic fuel consisting of coal fines treated with a40% solids tall oil emulsion at 0.5% by weight of coal versus thestarting materials.

[0022]FIG. 3 is a graphical Fourier Transform Infrared (FTIR) analysis,comparing a solid synthetic fuel consisting of coal fines treated with a40% solids tall oil emulsion at 0.75% by weight of coal versus thestarting materials.

[0023]FIG. 4 is a graphical Fourier Transform Infrared (FTIR) analysis,comparing a solid synthetic fuel consisting of coal fines treated with a40% solids tall oil emulsion at 1.0% by weight of coal versus thestarting materials.

[0024]FIG. 5 is a graphical Fourier Transform Infrared (FTIR) analysis,comparing a solid synthetic fuel consisting of coal fines treated with a40% solids tall oil emulsion at 1.25% by weight of coal versus thestarting materials.

[0025]FIG. 6 is a graphical Fourier Transform Infrared (FTIR) analysis,comparing a solid synthetic fuel consisting of coal fines treated with a40% solids tall oil emulsion at 1.5% by weight of coal versus thestarting materials.

[0026]FIG. 7 is a schematic illustration of a system for preparing anenhanced-tall-oil mix to apply to coal fines in order to produce thesynthetic fuel according to the method of the invention.

[0027]FIG. 8 is a schematic illustration of a system for preparing anenhanced-TDS-tall-oil mix or a non-enhanced-TDS-tall-oil mix to apply tocoal fines to produce the synthetic fuel according to the method of theinvention.

[0028]FIG. 9 is a graphical Fourier Transform Infrared (FTIR) analysis,illustrating chemical change in synthetic fuel according to theinvention relative to initial feedstock, the synthetic fuel comprisingcoal fines treated with an enhanced-TDS-tall-oil mix at 0.75% by weightof the coal.

[0029]FIG. 10 is a graphical Fourier Transform Infrared (FTIR) analysis,illustrating chemical change in synthetic fuel according to theinvention relative to initial feedstock, the synthetic fuel comprisingcoal fines treated with an enhanced-TDS-tall-oil mix at 1.0% by weightof the coal.

[0030]FIG. 11 is a graphical Fourier Transform Infrared (FTIR) analysis,illustrating chemical change in synthetic fuel according to theinvention relative to initial feedstock, the synthetic fuel comprisingcoal fines treated with an enhanced-TDS-tall-oil mix at 1.25% by weightof the coal.

[0031]FIG. 12 is a graphical-Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of samples of raw coal fines andof the enhanced-tall-oil-mix that are representative of samples used toproduce a synthetic fuel comprising 99% coal fines and 1.0%enhanced-tall-oil-mix.

[0032]FIG. 13 is a graphical Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of samples of raw coal fines andof the enhanced-tall-oil-mix that are representative of samples used toproduce a synthetic fuel comprising 99.15% coal fines and 0.85%enhanced-tall-oil-mix.

[0033]FIG. 14 is a graphical Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of samples of raw coal fines andof the enhanced-tall-oil-mix that are representative of samples used toproduce a synthetic fuel comprising 99.25% coal fines and 0.75%enhanced-tall-oil-mix.

[0034]FIG. 15 is a graphical Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of a synthetic fuel productproduced comprising 99.0% coal fines and 1.0% enhanced-tall-oil-mix.

[0035]FIG. 16 is a graphical Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of a synthetic fuel productproduced comprising 99.15% coal fines and 0.85% enhanced-tall-oil-mix.

[0036]FIG. 17 is a graphical Fourier Transform Infrared (FTIR) analysisshowing the chemical signature curves of a synthetic fuel productproduced comprising 99.25% coal fines and 0.75% enhanced-tall-oil-mix.

[0037]FIG. 18 is a comparison of three different synthetic fuel productsof the present invention compared to a conventional synthetic fuelproduct.

DETAILED DESCRIPTION OF THE INVENTION

[0038] The preferred embodiment of the invention is a method of creatinga tall-oil-based emulsion 20 for spraying coal fines to effect achemical change in the coal and to produce a synthetic fuel. Althoughthe following description illustrates a batch system of production, anautomated system can, of course, also be employed. Tall oil is heated toapproximately 185 degrees F. and piped into a mixing mill. At the sametime, water containing the emulsifying agent is piped into the mill. Inthe Preferred Embodiment, the emulsifying agent is a nonylphenolethoxylate surfactant with 70 moles of ethoxilation proportioned at 1%by weight of final emulsion, based upon a 100% active form of surfactantand adjusted accordingly for aqueous forms that maybe less than 100%active. For example, a 70% active form of the surfactant will require a1.43% addition rate. The water and the emulsifying agent are heated toapproximately 70 degrees F. before entering the mixing mill. The rate atwhich the pitch and the surfactant and water solution are combineddetermines the final solids content of the emulsion, which, in the caseof the Preferred Embodiment, is 40%. The mixing mill applies a shearmotion on the tall oil, breaking the oil into small globules which thenbecome suspended in the water solution. The surfactant aids theemulsification process and serves to keep the tall oil globules fromcoalescing with one another. The greater the shear applied, the smallerthe tall oil globules formed. In general, the smaller the globules, themore stable and homogeneous is the finished tall oil emulsion. Theweight of the finished tall oil emulsion 20 at 40% solids content isapproximately 8.32 lbs. per gallon.

[0039] As is illustrated in FIG. 1, the tall oil emulsion 20 isnozzle-sprayed into free-falling coal fines 22 from a number of anglesand sides so as to promote maximal contact with the coal fines 22. Inthe Preferred Embodiment, the coal fines 22 are sprayed in free fallfrom a conveyor 16 into a hopper 30. As shown in FIG. 1, a first spraynozzle 23 and a second spray nozzle 24 are located at a first angle anda second angle, respectively, with respect to the free-falling coalfines 22. This results in emulsion-treated coal fines 25, which are thenintroduced into a pug mill (not shown) to further facilitate evendistribution of the emulsion throughout the coal fines 25. Thereafter,the emulsion-treated coal fines 25 (solid synthetic fuel) are conveyedto a stack-out pile (not shown), or may be agglomerated, such aspelletizing or briquetting (not shown). The use of dryers (not shown)may also be used to facilitate the evaporation of the water off theemulsion-treated coal fines 25. It is, however, a desired feature ofthis method to minimize the need for drying and removal of excess waterby emulsifying the tall oil in advance of application. This facilitatesaccurate control of the amount of tall oil solids and water (tall oilemulsion 20) applied.

[0040]FIG. 2 through FIG. 6 show data taken from Fourier TransformInfrared (FTIR) analyses of samples containing varying degrees of talloil emulsion combined with coal fines (referred to as the “product”),compared to analyses of samples of the tall oil emulsion and coal finestaken separately (referred to as “simple mixture”). The data suggestthat, when coal fines are brought together with tall oil mix accordingto the method of the present invention, a chemical reaction takes placebetween the coal fines and the tall oil that results in synthetic fuel.These figures reflect amounts of tall oil emulsion (at 40% solids) addedfrom 0.5% to 1.5% by weight of coal, as seen in Tables 1-5 shown below.The non-destructive FTIR analyses are able to explore coal's functionalgroup content of the coal. “Functional group” refers to chemical speciesbonded to aromatic carbon ring structure sites where chemical reactionscommonly take place. This analytical technique identifies molecularvibrations due to the absorption of infrared radiation by functionalgroups with characteristic absorption bands. Such testing is able toascertain the presence of significant chemical changes in a sample ofthe coal fines treated with the tall-oil emulsion, in comparison withun-treated coal fines. TABLE 1 Comparis n fFTIR Results for Parent Feedand Fuel Product 0.5% binder Absortion peak wave Possible peak Peak areafor Peak area for Percent number in cm⁻¹ identification parent feed fuelproduct change 3386 hydroxyl groups 45.5800 41.9962 9 3037 aromatic CH3.1771 3.0112 6 2916 aliphatic CH 41.1173 39.8782 3 1596 aromatic ring64.4261 62.2182 4 enhanced by OH bonded C═O group 1439 aliphatic CH₂ and25.8677 24.1699 7 CH₃ 1373 cyclic CH₂ 0.8716 0.9178 5 1258 C—O and C—O—C0.9876 0.9981 1 1174 C—O and C—O—C 5.2676 6.6218 26 1102 ethers, esters1.1618 0.0000 removed 1032 C—O and Si—O 33.5047 21.7171 54 918 alkenes,aldehydes 0.9291 0.0000 removed 858 1.9846 2.6313 33 806 polycyclicaromatic 4.7183 4.2177 12 skeletal structure 749 2.5517 3.2966 29 698aromatic substitution 1.8247 1.0264 78 535 carboxyl groups, 16.830513.7271 23 thiophenes, heterocyclics 469 Branched and cyclo- 9.63745.9012 63 alkanes and aliphatic ethers 424 carbonyl, ketones 1.11550.6342 76 ave. 27

[0041] TABLE 2 0.75% Comparison of FTIR Results for Parent Feed and FuelProduct binder Absorption peak wave Possible peak Peak area for Peakarea for Percent number in cm⁻¹ identification parent feed fuel productchange 3386 hydroxyl groups 45.0112 44.5350 1 3043 aromatic CH 3.09673.0786 1 2916 aliphatic CH 39.6251 42.5361 7 1596 aromatic ring 62.933262.3944 1 enhanced by OH bonded C═O group 1436 aliphatic CH₂ and 25.264024.3238 4 CH₃ 1370 cyclic CH₂ 0.8522 0.9002 6 1258 C—O and C—O—C 1.06870.9906 8 1174 C—O and C—O—C 4.9082 6.1183 25 1111 ethers, esters 1.02830.7372 39 1032 C—O and Si—O 33.5262 26.1635 28 918 alkenes, aldehydes0.6674 0.5090 31 861 1.9388 2.3177 20 803 polycyclic aromatic 4.61274.3129 7 skeletal structure 749 2.4942 2.8145 13 698 aromaticsubstitution 1.8536 1.4927 24 535 carboxyl groups, 16.8466 15.4300 9thiophenes, hererocyclics 472 Branched and cyclo- 9.6514 8.0703 20alkanes and aliphatic ethers 427 carbonyl, ketones 1.0842 0.8475 28 ave.15

[0042] TABLE 3 Comparison of FTIR Results for: Parent Feed and FuelProduct 1% binder Absorption peak wave Possible peak Peak area for Peakarea for Percent number in cm⁻¹ identification parent feed fuel productchange 3386 hydroxyl groups 45.5033 42.8306 6 3043 aromatic CH 3.09042.9870 3 2916 aliphatic CH 40.0238 42.3137 6 1593 aromatic ring 62.935561.5011 2 enhanced by OH bonded C═O group 1436 aliphatic CH₂ and 25.263025.1519 0 CH₃ 1370 cyclic CH₂ 0.8533 0.9634 13 1252 C—O and C—O—C 1.00991.0838 7 1168 C—O and C—O—C 5.1077 5.4345 6 1108 ethers, esters 0.98520.7538 31 1032 C—O and Si—O 28.6857 23.2038 24 915 alkenes, aldehydes0.7853 0.4584 71 861 1.9390 2.2944 18 803 polycyclic aromatic 4.61684.2883 8 skeletal structure 749 2.4959 2.9337 18 698 aromaticsubstitution 1.5561 1.3995 11 535 carboxyl groups, 14.8296 12.9285 15thiophenes, heterocyclics 469 Branched and cyclo- 8.2766 6.7904 22alkanes and aliphatic ethers 427 carbonyl, ketones 1.0709 0.9498 13 ave.15

[0043] TABLE 4 1.25% Comparison of FTIR Results for Parent Feed and FuelProduct binder Absorption peak wave Possible peak Peak area for Peakarea for Percent number in cm⁻¹ identification parent feed fuel productchange 3386 hydroxyl groups 45.9981 46.5494 1 3043 aromatic CH 3.08402.8547 8 2916 aliphatic CH 40.0739 42.7524 7 1599 aromatic ring 62.552561.3507 2 enhanced by OH bonded C═O group 1436 aliphatic CH₂ and 24.675423.8952 3 CH₃ 1373 cyclic CH₂ 0.8542 0.9535 12 1252 C—O and C—O—C 1.11191.0077 10 1177 C—O and C—O—C 5.0252 5.9054 18 1108 ethers, esters 0.98640.7013 41 1032 C—O and Si—O 33.3901 26.2324 27 918 alkenes, aldehydes0.7939 0.4602 73 858 1.9394 2.1960 13 800 polycyclic aromatic 4.62104.2892 8 skeletal structure 749 2.4977 2.9254 17 698 aromaticsubstitution 1.8269 1.4589 25 535 carboxyl groups, 16.8414 15.9147 6thiophenes, heterocyclics 472 Branched and cyclo- 9.6561 8.0995 19alkanes and aliphatic ethers 427 carbonyl, ketones 1.1232 0.9406 19 ave.17

[0044] TABLE 5 Comparison of FTIR Results for Parent Feed and FuelProduct 1.5% binder Absorption peak wave Possible peak Peak area forPeak area for Percent number in cm⁻¹ identification parent feed fuelproduct change 3380 hydroxyl groups 46.4957 41.3142 13 3043 aromatic CH3.0773 2.8595 8 2916 aliphatic CH 40.3441 43.5053 8 1596 aromatic ring61.8963 61.6030 0 enhanced by OH bonded C═O group 1436 aliphatic CH₂ and24.6763 23.9078 3 CH₃ 1373 cyclic CH₂ 0.8551 1.0021 17 1255 C—O andC—O—C 1.0412 0.9865 6 1171 C—O and C—O—C 5.0542 6.4190 27 1108 ethers,esters 1.1682 0.6352 84 1029 C—O and Si—O 33.4953 27.7601 21 918alkenes, aldehydes 0.8031 0.4636 73 861 1.9397 2.3452 21 800 polycyclicaromatic 4.6251 4.1618 11 skeletal structure 749 2.4987 3.0571 22 695aromatic substitution 1.8145 1.5304 19 535 carboxyl groups, 16.814515.9566 5 thiophenes, heterocyclics 469 Branched and cyclo- 9.67178.2476 17 alkanes and aliphatic ethers 424 carbonyl, ketones 1.07850.9090 19 ave. 21

[0045] In order to obtain the spectra shown in FIG. 2 through FIG. 6,the samples were imbedded in potassium bromide pellets, and light in theinfrared range of 400-4000 cm⁻¹ was passed through the pellets. Thechemical bonds present determine the absorption spectrum. For example,typically triple bonds and hydrogen stretching are represented by aspectral region of 4000 cm⁻¹ to approximately 1800 cm¹. Double bondedstructures and aromatic structures have an FTIR range of approximately1800 cm⁻¹ to 1400 cm⁻¹. Single bond structures consisting of variousaromatic substitution bonding have an FTIR range from 1000-400 cm⁻¹.Supporting Fourier Transform Infrared (FTIR) data from otherlaboratories not using potassium bromide pellets and preparing sampleswith other methodology yield similar results.

[0046] Separate scans of the samples were done and the baselinesadjusted for accuracy in the context of comparing the base materials andthe manufactured fuel product, and the results can be seen in FIG. 2through FIG. 6. The differences in peak absorption is a strongindication that the coal fines do in fact react with the tall oilemulsion.

[0047] In a further embodiment of the tall-oil mix described above, anenhanced-tall-oil mix 708 is produced by adding an enhancer 704 to thetall-oil mix 702 in a ratio of about approximately 10% enchancer 704 toapproximately 90% tall-oil mix 702. See FIG. 7. Suitable enhancers 704include such substances as poly vinyl acetate (PVA) and/or ethyl vinylacetate (EVA), urea, glycol, lignosulfonate, vegetable materials, suchas beet sugar bottoms, molasses, corn bottoms, brewery bottoms,vegetable tall oil, vegetable oil, vegetable pitch, and/or spent fryingoil. One or more of these enhancers 704 may be added in step 706 to thefinished tall-oil mix (emulsion) 702, to the tall-oil or tall-oil pitchbefore emulsification, or applied simultaneously as with step 710 withthe tall-oil emulsion to coal fines 712. In an enhanced tall-oil mix 708using vegetable oil or spent frying oil, the oil is combined withtall-oil pitch 702 in a ratio of approximately 1 part vegetable oil orspent frying oil to approximately 3 parts tall-oil pitch 702. Theenhanced-tall oil-mix 708 is then applied in step 710 to the coal fines712 to form a synthetic fuel 714.

[0048] A further development of the synthetic fuel according to themethod of the present invention includes a synthetic fuel 838 that isproduced by forming an enhanced-TDS-tall-oil mix 830 and applying it tocoal fines 712. The enhanced-TDS-tall-oil mix 830 is formed by combiningtar decanter sludge (TDS) 818, a by-product of the steel industry, and,preferably but optionally, light cycle oil (LCO) 820 with acombination-tall-oil-mix 810. The combination-tall-oil-mix 810preferrably is comprised of the enhanced tall-oil mix 708, a causticsolution 804, and water 806.

[0049] In the preferred embodiment, the synthetic fuel 838 isapproximately 0.64% enhanced-TDS-tall-oil mix 830 and approximately99.36% coal fines 712, wherein the TDS 818 and LCO 820 compriseapproximately 0.29% and the combination-tall-oil mix 810 comprisesapproximately 0.35%. In this example the 0.35% combination-tall-oil-mix810 is comprised of approximately 83% of enhanced-tall-oil mix 708(which is comprised of approximately 55% enhancer 704, such as PVA, andapproximately 28% tall-oil mix 702), approximately 8% of a 20% causticsolution 804, and 9% water 806. The preferred embodiment uses a 20%caustic solution 804, but this is for convenience only. It is possibleto use the process and system of the present invention with a causticsolution 804 having a strength within the range of 5% to 40%. Thepercentage amount of the caustic solution 804 and water 806 are adjustedby conventional means according to the chosen strength of the causticsolution 804. It is further known that a 50% caustic solution 804 wouldbe too concentrated and interfere with the production of theenhanced-TDS-tall-oil mix 830 and the non-enhanced-TDS-tall-oil mix. Theratio of tall-oil mix 702 to enhancer 704, e.g., PVA or EVA emulsion,that forms the enhanced tall-oil mix 708 and provides the desiredchemical change in the production of the synthetic fuel 838, may varyover a very wide range, with an acceptable ratio of tall-oil mix 702being at least as low as 15% to a corresponding 85% or greater ofenchancer 704, e.g., PVA or EVA emulsion. Furthermore, the preferredratio of enhanced-TDS-tall-oil mix 830 is not limited to 0.64%, but isvariable within a range of approximately 0.5% to approximately 0.9%.Rates lower than approximately 0.5% may not provide the desired amountof chemical change when applied to the coal fines 712; rates higher thanapproximately 0.9% may not be economical. The enhanced-TDS-tall-oil mix830 is then applied to the coal fines 712 in order to produce thesynthetic fuel 838. As mentioned earlier, it is not necessary to add theLCO 820 to obtain the necessary chemical change to produce the syntheticfuel 838. It is advantageous to the process to do so, however, becausethe LCO 820 thins the TDS 818 and aids mixing.

[0050] In addition, although the use of the chemical enhancers 704 isadvantageous and is preferred when producing a synthetic fuel 838 withthe TDS 818 and LCO 820 additives, it is not necessary to use theenhanced tall-oil mix 708. Rather, a non-enhanced-tall-oil mix 802, i.e.a tall-oil mix 702 without added enhancers 704, is mixed with causticsolution 804 and water 806 to obtain a combination-tall-oil mix 810 thatis non enhanced, which is then combined with TDS 818 and LCO 820 toobtain a non-enhanced-TDS-tall-oil mix 832. The non-enhanced-tall-oilmix 802 comprises tall oil, tall-oil pitch, or any combination thereof,collectively tall oil mix 702, without the addition of chemical-changeenhancers 704. This non-enhanced-TDS-tall-oil mix 832 is then applied tothe coal fines 712 to produce the synthetic fuel 838.

[0051]FIG. 8 is a schematic illustration, showing the system 800 formixing by re-circulation a combination-tall-oil mix 810 with the TDS 818and LCO 820 to produce the enhanced-TDS-tall-oil mix 830 of the presentinvention. The same system 800 is also used to produce thenon-enhanced-TDS-tall-oil mix 832, but for purposes of illustration andsimplicity, reference shall be made to the production of theenhanced-TDS-tall-oil mix 830.

[0052] The system 800 includes a tank 822, having a tank inlet 816 and atank outlet 826, and a recirculating line 814, having an inlet 812 andan outlet 840, wherein the recirculating line 814 connects the tankinlet 816 with the tank outlet 826. As shown, heating means 824, such asa conventional heating unit, are included within the tank 822 and aconventional grinding pump 828 is installed in the recirculating line814 after the tank outlet 826.

[0053] In operation, the TDS 818 and LCO 820 are introduced into thetank 822 via tank inlet 816. Once in the tank 822, the TDS 818 and LCO820 are heated by the heating means 824 until they reach a desired,predefined temperature. In the preferred embodiment, the TDS 818 and LCO820 are heated until they reach about 123 degrees F. The TDS 818 and LCO820 may remain in the tank 822 until the desired temperature is reached,or the TDS 818 and LCO 820 may be circulated out the tank 822, throughthe recirculation line 814 and grinding pump 828, and back into the tank822 until they reach the desired temperature. The preferred embodimentuses the desired temperature of about 123 degrees F. for conveniencepurpose only. It would be readily apparent to one of ordinary skill touse a comparable temperature, such as a temperature within the range ofabout 100 to about 135 degrees F.

[0054] The combination-tall-oil mix 808, which is described in greaterdetail above, is introduced into the recirculating line 814 via theinlet 812 and fed into the tank 822 via tank inlet 816. In order tofacilitate the heating process within the tank 822, thecombination-tall-oil mix 808 is heated prior to its introduction intothe tank 822. For example, the combination-tall-oil mix 808 ispreferably heated to approximately 100 degrees F. Thus, when the warmedcombination-tall-oil mix 808 is introduced into the tank 822 containingthe heated TDS 818 and LCO 820, the previously heated TDS 818 and LCO820 are not unduly cooled. The heating of the combination-tall-oil mix808 is optional, as well as the prior heating of the TDS 818 and LCO820.

[0055] Once all components are in the tank 822, the combination-tall-oilmix 808, TDS 818, and LCO 820 are heated and subsequently passed out thetank outlet 826 and through the grinding pump 828, thereby producing theenhanced-TDS-tall-oil mix 830. In the preferred embodiment, theenhanced-TDS-tall-oil mix 830 reaches a desired, predefined, minimumtemperature prior to exiting the system 800. Specifically, theenhanced-TDS-tall-oil mix 830 reaches a temperature within the range ofapproximately 100 to 135 degrees F., with a preferred temperature ofapproximately 123 degrees F. It may be necessary to recirculate all ofthe ingredients until this preferred temperature is achieved.

[0056] In one embodiment in which recirculation is not desired orrequired, step 834, such as when the enhanced-TDS-tall oil mix 830 hasreached the predefined minimum temperature, the enhanced-TDS-tall-oilmix 830 is then discharged from the recirculating line 814 via theoutlet 840, ready to be applied, in step 836, to the coal fines 712 toproduce the synthetic fuel 838. In a second embodiment in whichrecirculation is desired or required, such as to enable theenhanced-TDS-tall-oil mix 830 to reach the predefined minimumtemperature, step 834, the enhanced-TDS-tall-oil mix 830 is notdischarged from the recirculating line 814, but rather is transportedback into the tank 822 via the tank inlet 816. In this secondembodiment, the enhanced-TDS-tall-oil mix 830 is passed through the tank822 for further heating. This recirculating of the enhanced-TDS-tall-oilmix 830 through the grinding pump 828 is repeated until theenhanced-TDS-tall-oil mix 830 achieves the desired predefined minimumtemperature and/or homogeneous mixture. Once the desired temperatureand/or homogeneous mixture is achieved, the enhanced-TDS-tall-oil mix830 is discharged from the recirculating line 814 via the oulet 840 andapplied, step 836, to the coal fines 712 as described above.

[0057] This is merely an example of a system 800 that is suitable forproducing the enhanced-TDS-tall-oil mix 830 or the non-enhanced-TDStall-oil mix 832 according to the invention. Futhermore, the system 800is designed to make separate batches of such enhanced-TDS-tall-oil mix830 or the non-enhanced-TDS tall-oil mix 832. The system 800 isdescribed in these terms for convenience purposes only. It would bereadily apparent to one of ordinary skill in the relevant art to use acomparable system without departing from the scope of the presentinvention.

[0058] FIGS. 9-11 are graphical representations of the results ofFourier Transform Infrared spectroscopy studies (FTIR) of test samplesof the synthetic fuel 838. The enhanced-TDS-tall-oil mix 830 was mixedwith coal fines 712 and then compressed to form the finished syntheticfuel product 838. The samples of coal were of bituminous metallurgicalcoal. As seen in each of the figures, there are clear differences in thespectra between the raw coal fines 712 and the synthetic fuel 838,indicating that the final product has a basic chemical composition thatis measurably different from that of the initial feedstock.

[0059]FIG. 9 shows the FTIR curves for raw coal fines 712 and asynthetic fuel comprising 99.25% coal fines 712 and 0.75%enhanced-TDS-tall-oil mix 830. As seen, a synthetic-fuel curve 920 showsclear differences from a coal-fines-curve 910. The percentage ofchemical change documented with these results is 32%. FIG. 10 shows theFTIR curves for a raw coal fines 712 and a synthetic fuel comprising99.0% coal fines 712 and 1.0% enhanced-TDS-tall-oil mix 830. Asynthetic-fuel curve 1020 shows clear differences from acoal-fines-curve 1010. The percentage of chemical change documented withthese results is 42%. FIG. 11 shows the FTIR curves for raw coal fines712 and a synthetic fuel 838 comprising 98.75% coal fines 712 and 1.25%enhanced-TDS-tall-oil mix 830. A synthetic-fuel curve 1120 shows cleardifferences from a coal-fines-curve 1110. The percentage of chemicalchange documented with these results is 45%.

[0060] FIGS. 12-17 illustrate the results of Fourier Transform Infraredspectroscopy (FTIR) analysis on raw coal fines 712, on theenhanced-tall-oil-mix 708 comprising 90% tall-oil-mix 702 and 10% PVA704, and on a synthetic fuel 714 comprising the coal fines 712 and theenhanced-tall-oil-mix 708. The results indicate the amount of chemicalchange between the raw coal fines 712 and the synthetic fuel 714. Theanalysis was performed on coal samples treated with theenhanced-tall-oil-mix 708 at three different addition rates by weight ofcoal: 0.75% (Test 1), 0.85% (Test 2), and 1.0% (Test 3). In addition,signature curves of a mathematical weight combination of the chemicalsignatures of the representative samples of the raw coal fines 712 andthe enhanced-tall-oil-mix 708 for the particular by-weight additionrates were also plotted.

[0061]FIG. 12 shows the chemical signature 1201 of a sample of coalfines 712 and the chemical signature 1202 of a representative sample ofthe enhanced-tall-oil-mix 708, the samples being representative of thesamples used in Test 1. Similarly, FIG. 13 shows the chemical signature1301 of a sample of coal fine 712 and the chemical signature 1302 of theenhanced-tall-oil-mix 708 representative of the samples used in Test 2,and FIG. 14 shows the chemical signatures 1401 and 1402 for the samplesof coal fines 712 and the enhanced-tall-oil-mix 708, respectively, thatare representative of the samples used in Test 3.

[0062] FIGS. 15-17 show the chemical signature curves for the syntheticfuels 714 and the weight combination curves for Test 1, 2, and 3. FIG.15 shows a signature curve 1501 for a synthetic fuel 714 comprising99.0% coal fines 712 and 1.0% enhanced-tall-oil-mix 708 and a signaturecuve 1502 for the mathematical combination of the chemical signatures ofthe raw coal fines 712 and the enhanced-tall-oil-mix 708. A total netchange of 29% was observed between the spectra of the synthetic fuel 714and that of the weight combination spectra in Test 1. FIG. 16 shows asignature curve 1601 for a synthetic fuel comprising 99.15% coal fines712 and 0.85% enhanced-tall-oil-mix 708 and a signature cuve 1602 forthe mathematical combination of the chemical signatures of the raw coalfines 712 and the enhanced-tall-oil-mix 708. A total net change of 24%was observed between the spectra of the synthetic fuel 714 and that ofthe weight combination spectra. FIG. 17 shows a signature curve 1701 fora synthetic fuel 714 comprising 99.25% coal fines 712 and 0.75%enhanced-tall-oil-mix 708 and a signature curve 1702 for themathematical combination of the chemical signatures of the raw coalfines 712 and the enhanced-tall-oil-mix 708. A total net change of 20%was observed between the spectra of the synthetic fuel 714 in Test 3 andthat of the weight combination spectra.

[0063]FIG. 18 shows four FTIR analysis curves 1801-1804 of the chemicalcomposition of four different compositions of the synthetic fuel 714according to the invention, produced by treating bituminous coal fines712 with various compositions of a tall-oil-mix 702 comprising a 40%solids tall-oil-pitch emulsion. Curve 1801 shows the chemical signaturefor a synthetic fuel 714 produced by treating the coal fines 712 with anenhanced tall-oil-mix 798 comprising 25% vegetable oil and 75% of thesolids of a 40% tall-oil-pitch emulsion; curvet 1802 shows the chemicalsignature for a fuel in which the coal fines 712 are treated with anenhanced tall-oil-mix 708 comprising 25% vegetable-tall-oil pitch and75% of the solids of a 40% tall-oil-pitch emulsion; curve 1803 shows thechemical change signature for a fuel in which the coal fines 712 aretreated with an enhanced tall-oil mix 708 comprising 25% crude tall oiland 75% of the solids of a 40% tall-oil-pitch emulsion; and curve 1804shows the chemical signature of a synthetic fuel 714 in which the coalfines 712 are treated with just a 40% solids tall-oil-pitch emulsion.

[0064] It further shall be understood that variations in the formulationof the enhanced tall-oil mix 708, the enhanced-TDS-tall-oil mix 830, andthe non-enhanced-TDS-tall-oil mix 832 may be contemplated by one skilledin the art without limiting the intended scope of the method accordingto the invention herein disclosed and as defined by the followingclaims. In addition, the present invention is described using bituminouscoal fines for convenience purpose only. It should be understood thatthe system and process for making synthetic fuel and synthetic fuel ofthe present invention also can be made using sub-bituminous coal fines.

What is claimed is:
 1. A method of producing a synthetic fuel, saidmethod comprising the steps of: (a) preparing an enhanced tall-oil mixcomprising a tall-oil-mix and a chemical change enhancer; and (b)reacting said enhanced tall-oil mix with coal fines so as to obtain saidsynthetic fuel.
 2. The method of claim 1, wherein said enhancedtall-oil-mix includes approximately 10% of said chemical-changeenhancer.
 3. The method of claim 1, wherein said chemical-changeenhancer includes one or more of materials from a group consisting ofPVA, EVA, urea, glycol, lignosulfonate, beet sugar bottoms, molasses,corn bottoms, brewery bottoms, vegetable tall oil, vegetable oil, andspent frying oil.
 4. The method of claim 3, wherein if saidchemical-change enhancer is vegetable oil or spent frying oil, saidtall-oil-mix includes approximately 25% of said chemical-changeenhancer.
 5. The method of claim 1, wherein said coal fines arebituminous coal fines.
 6. The method of claim 1, wherein said preparingsaid enhanced tall-oil-mix of said step (a) is performed prior to saidstep (b).
 7. The method of claim 1, wherein said preparing said enhancedtall-oil-mix of said step (a) occurs simultaneous with said step (b). 8.A synthetic fuel produced by the method of claim
 1. 9. The syntheticfuel of claim 8, wherein said coal fines are metallurgical bituminouscoal fines.
 10. A method of producing a synthetic fuel, said methodcomprising the steps of: (a) combining a tall-oil mix with a causticsolution and water to form a combination tall-oil mix; (b) combiningsaid combination tall-oil mix with tar decanter sludge to form aTDS-tall-oil mix; and (c) reacting said TDS-tall-oil mix with coal finesso as to obtain said synthetic fuel.
 11. The method of claim 10, whereinsaid coal fines are bituminous metallurgical coal fines.
 12. The methodof claim 10, wherein said step (a) includes the step of adding achemical change enhancer to said tall-oil mix to obtain anenhanced-TDS-tall-oil mix in said step (b), and said step (c) includesreacting said enhanced-TDS-tall-oil mix with said coal fines.
 13. Themethod of claim 12, wherein said chemical-change enhancer includes oneor more of materials form a group consisting of PVA, EVA, urea, glycol,lignosulfonate, beet sugar bottoms, molasses, corn bottoms, brewerybottoms, vegetable tall oil, vegetable oil, and spent frying oil. 14.The method of claim 10, wherein a thinning agent is added to saidenhanced-TDS-tall-oil mix.
 15. The method of claim 14, wherein saidthinning agent is light cycle oil.
 16. The method of claim 12, whereinapproximately 0.5% to approximately 0.9% of said synthetic fuel is saidenhanced-TDS-tall-oil mix.
 17. The method of claim 16, whereinapproximately 0.64% of said synthetic fuel is said enhanced-TDS-tall-oilmix.
 18. The method of claim 16, wherein said approximately 0.64% ofsaid enhanced-TDS-tall-oil mix is approximately 0.29% tar decantersludge and a thinning agent and approximately 0.35% of said combinationtall-oil mix.
 19. The method of claim 18, wherein said 0.35% of saidcombination tall-oil mix comprises approximately 28% tall oil mix,approximately 55% chemical-change enhancer, approximately 8% of a 20%caustic solution, and approximately 9% water.
 20. The method of claim12, wherein said enhanced-TDS-tall-oil mix includes at leastapproximately 15% of said tall-oil-mix.
 21. The method of claim 10,further comprising the step of: (d) heating said tar decanter sludgeprior to forming said TDS-tall-oil mix.
 22. The method of claim 10,further comprising the step of: (d) grinding said TDS-tall-oil mix priorto said step (c).
 23. The method of claim 22, further comprising thestep of: (e) recirculating said TDS-tall-oil mix through said step (d)prior to said step (b).
 24. The method of claim 24, further comprisingthe step of: (d) heating said tar decanter sludge and said thinningagent prior to forming said TDS-tall-oil mix.
 25. The method of claim24, further comprising the step of: (e) grinding said TDS-tall-oil mixprior to said step (c).
 26. The method of claim 25, further comprisingthe step of: (f) recirculating said TDS-tall-oil mix through said step(d) prior to said step (c).
 27. The method of claim 10, furthercomprising the step of: (d) heating said TDS-tall-oil-mix to atemperature within a range of approximately 100 to approximately 135degrees F. after said step (b).
 28. The method of claim 27, wherein saidTDS-tall-oil mix is heated to approximately 123 degrees F.
 29. Themethod of claim 10, further comprising the step of: (d) heating saidcombination tall-oil-mix prior to said step (b).
 30. The method of claim29, wherein said combination tall-oil-mix is heated to approximately 100degrees F.
 31. A synthetic fuel produced by the method of claim
 10. 32.A synthetic fuel comprising: coal fines; and a chemical change agentcomprising a tall-oil mix, a caustic solution and water, and tardecanter sludge (TDS); wherein said chemical change agent and said coalfines are combined and processed so as to maximize contact between saidmix and said raw coal.
 33. The synthetic fuel of claim 32, wherein saidchemical change agent further comprises a thinning agent.
 34. Thesynthetic fuel of claim 33, wherein said thinning agent is light cycleoil.
 35. The synthetic fuel of claim 31, wherein said chemical changeagent further comprises an enhancer.
 36. The synthetic fuel of claim 35,wherein said enhancer includes one or more of materials from a groupconsisting of PVA, EVA, urea, glycol, lignosulfonate, beet sugarbottoms, molasses, corn bottoms, brewery bottoms, vegetable tall oil,vegetable oil, and spent frying oil.
 37. The synthetic fuel of claim 32,wherein said coal fines are metallurgical bituminous coal fines.
 38. Asynthetic fuel comprising coal fines and an enhanced-tall-oil-mix,wherein said enhanced-tall-oil-mix comprises a tall-oil mix and achemical-change enhancer, wherein said coal fines are treated with saidenhanced-tall-oil-mix so as to maximize contact between said coal finesand said enhanced-tall-oil-mix.
 39. The synthetic fuel of claim 38,wherein said enhanced-tall-oil-mix comprises approximately 90%tall-oil-mix and 10% chemical-change enhancer.
 40. The synthetic fuel ofclaim 38, wherein said chemical-change enhancer includes one or more ofmaterials from a group consisting of PVA, EVA, urea, glycol,lignosulfonate, beet sugar bottoms, molasses, corn bottoms, brewerybottoms, vegetable tall oil, vegetable oil, and spent frying oil. 41.The synthetic fuel of claim 40, wherein if said chemical-change enhanceris vegetable oil or spent frying oil, said tall-oil-mix includesapproximately 25% of said chemical-change enhancer.
 42. The syntheticfuel of claim 38, wherein said coal fines are metallurgical bituminouscoal fines.